Professional Documents
Culture Documents
Surender Kumar
Deputy Director,NPTI
Boiler Schematic
Water & Steam cycle Fuel System Air & flue gas Flow Path Ash/ rejects Handling System
Performance Parameters
Steps &nvolved &n Boiler Energy Audit Data collection !ser"ations and Analysis #$ploration for energy conser"ation measures %eport preparation
*ata Collection
+nit
*etails at ,ormal cont% rating$ ,C ////// 1ater 0ube Single *rum 234%53 788 8:9 <4%72 234%53 828%2 :589 792%3 <33 :39 8:9 3:7 3<9 :%35
C C C C
Actual
,o of coal burners Primary Air Fuel ,o of mills in operation -ill loading Air temperature at mill inlet after tempering Air # fuel mixture temperature after leaving mills 0otal coal fired Air # Fuel atio
,o tp! ,o ; oC
oC
tp!
EEEEEEEEEEtp! at coal EEEEEEEEgrind EEEEEEEEEEE; t!roug! EEEEEEEEmes! EEEEEEEEEEEE.1 EEEEEEEE = ,o of mills EEEEEEEEE6EEEEEEEE DEEEEEEEEEE
*esign coal parameter -oisture As! =olatile matter Fixed carbon "G& EEEEE; EEEEE; EEEEE; EEEEE; EEEEE;
+nit
9
379 -1 899 -1 7728 799< <2: 48: 254 :F5 587 752 777F 795: F98 4<< 827 582 752
C C C C C
C
9
C C
779 -1
54%95 3%32 9%55 9%<8 2%85 73%9 :7%9 5899 3:%9 35%9 73%9 :7%9
Ambient temperature Boiler loading -otor electrical parameters B.1$ .=A$ Pf$ A$ =$ "?$ 0"*C etc% Surface temperatures of insulation and boiler surfaces 't!er important Parameters +nit load of t!e plant *ate ) time of measurement &nstruments used for measurement Frequency of t!e measurement
-easurements ) 'bservations
Soot blo(ers operation 0ripping Performance of economiser$ air pre!eaters$ >P 6 "P !eater from past records Combustion control system # practice follo(ed -ills performance &f plant !as online and off line tools for performance evaluation of main equipment and B'P equipment # t!en details of t!ese tools Plant side initiatives to improve t!e performance and efficiency of t!e boiler
&nstruments
&nstruments equired
Po(er AnalyserD +sed for measuring electrical parameters suc! as .1$ .=A$ pf$=$ A and "? 0emperature &ndicator ) Probe StroboscopeD 0o measure t!e speed of t!e driven equipment and motor Sling !ygrometer or digital !ygrometer Anemometer Available 'n line instruments at t!e site
&nstruments equired
Digital &anometer of suita!le range and appropriate pro!es for measurement of pressure head and "elocity head Additional pressure gauges with appropriate range of measurement and cali!rated !efore audit Flue gas analy,ers / orsat apparatus @nfrared pyrometers Pressure gauges Steam trap tester / Altra sonic lea) detectors
Ensure during AuditingD >oad on t!e boiler to be by and large constant and represent average loading and normal operation ,o soot blo(ers operated ,o intermittent blo( do(n Preparedness for simultaneous data measurements and collection of various parameters% *emo exercise for one set of measurement and observation
-easurement >ocations
Flue gas analysis at air pre!eaters inlet 6 out let 0emperature of flue gas at air pre!eaters inlet 6 out let Fly as! sampling at t!e economiser outlet and ESP !oppers for unburnt carbon in fly as! Sample of bottom as! from !opper or scrapper Sample of ra( coal from C Feeder of t!e mill for proximate and ultimate analysis of fuel and gross calorific value% Pulverised coal samples from eac! mill for sieve analysis% Sample of mill reGects for GC=%
*ata Analysis
'bservations ) Analysis
'perating efficiency of t!e boilerD "eat loss due to dry flue gas losses "eat loss due to moisture in fuel "eat loss due to !ydrogen Bmoisture of burning !ydrogenC "eat loss due to combustibles in refuse "eat loss due to radiation +n accounted losses as per t!e contract (it! t!e Boiler Supplier
9 H2
100 GCV
Where H0 = )g of H0 in 1 )g of fuel
Where AASEActual mass of air supplied Humidity E humidity of air in )g/)g of dry air
Boiler"eat Balance
8%8; :%3;
Heat loss due to wet flue gas Heat loss due to moisture in fuel Heat loss due to moisture in air Heat loss due to un!urnts in residue Heat loss due to radiation & other unaccounted loss
7;
B'&>E
9%5; 7; 7;
<4;
coal3
-o esta!lish air to coal ratio of the mills /ton of air per
ton of coal3
-o e"aluate specific coal consumption of the unit
/)g /)Wh3
(ompare the actual consumption with design/pg test
"alues
Suggest ways to optimise energy consumption
"er"iew of system includes mills* %( feeders* PA fans* seal air fans*mill reject handling system and associated ducts* piping* "al"es and dampers* lu!rication system* thermal insulation status of mills/pa fans ducts/piping etc9
a( CoalG
>(?* ash content* "olatile matter* fi$ed car!on* total moisture*and H>@ "alue of coal9 &ill fineness /< passing through 022 mesh3* %unning hours of mill grinding elements with material composition of each part* @ndi"idual %(F coal integrator readings !e compared with o"erall coal integrator readings9
Pulverised CoalG
-ill
eGect CoalG
Ash content and gross calorific "alue of mill rejects* FlyAsh* Bottom Ash and (om!usti!les in fly ash and !ottom ash & >(?9 ?iscosity* moisture* mechanical impurities and appearance of lu!ricating oil of mill gear!o$es9
-ill reGects
C'-B+S0&', C',0 '>$ E/CESS A& A,* C'>* A& &,G ESS
1!ile conducting t!e study$ t!e follo(ing need to be verifiedD Present e$cess air and comparison with P> test or design "alue (om!ustion control systems installed and status of operation* cali!ration systems &onitoring and controlling mechanism for o$ygen* e$cess air and reporting systems in place #ffect of e$cess air on !oiler performance #$cess air with respect to !oiler load "ariation (old air infiltration in to the system = o!ser"e the present method of measurement* estimation* freBuency of measurement for estimating the losses and control mechanisms initiated9
Alternati"ely* if the ( 0< is measured in the e$haust gases then the air lea)age is estimated !y
tph
Boiler Soot Deposits* High #$cess Air * Air inlea)ages !efore the com!ustion cham!er* Fow Feed Water -emperature * Passing dampers and poor air heater seals * Higher ele"ation !urners in ser"ice* @mproper com!ustionI
Incomplete Combustion
Poor milling i9e9 (ourse grinding* Poor air/fuel distri!ution to !urners* Fow com!ustion air temperature* Fow primary air temperature* Primary air "elocity !eing "ery high/"ery low* Fac) of adeBuate fuel/air mi$ingI99
Air in+lea)age through man holes* peep holes* !ottom seals* air heater seal lea)age* une"en distri!ution of secondary air* inaccurate samples/analysis9 0 controlI9
adiation and convection !eat loss% (asing radiation* sensi!le heat in refuse* !ottom water seal operation* not much controlla!le !ut !etter maintenance of casing insulation can minimi,e the loss9
Blo(do(n%
1 < of !low down carries a 2915< heat added* in the !oiler* 2904< heat is reBuired to ma)e up accounts to 2980< so !low down to !e adhered to the chemist reBuirement9
Super heated steam with high enthalpy is used9 1< of steam may !e reBuired* contains 2960< heat content* to ma)e up the loss another 2904< heat to !e added to feed water resulting total heat loss of 2975<9 FreBuency of soot !lowing must !e carefully planned9
as is = the actual system efficiency CMWh = uel costs in Rs!MWh "here MWh# refers to ener$y in the fuel P% = plant loa& factor as a fraction
Parameter Excess air at boiler exit ; Excess air at AP" exit FG temp% at AP" exit 9c *ry Flue gas loss ; "eat loss due to C' ; ;
*esign 7F%9 3<%9 7:2%9 8%9< 9 9%73 8%F8 9%F9 9%82 9%74 9%8 73%84 <4%:5
measured 35%2 88%2 724%2 <%<F 9 9%7< 8%4< 9%9F 9%8F 9%79
'bservation Excess Air and cold air &ngress also causes &* fan loading Excess FG temp% at AP" Causes ) Actions 1orn out seals and !eat 0ransfer elements-Attended >ea.age t!roug! peep6port !oles-Attended Soot formation on t!e !eat transfer area- S B done esults 3%<5; effciciency impr% in eduction Coal consumption By 4::F9 06A s%25%9F saving B s% <:4 60C
"eat loss due to moisture in air ; "eat loss due to moisture and "3 in fuel ; "eat loss due to unburnt in as! Sensible !eat loss in as! ; Surface and unaccounted losses ; *esign margin ; 0otal !eat losses ;BcorrectedC 0!ermal efficiency ; ;
7:%F5 <8%94
'ptimi?ation of PA to SA
0ype +nit PAF A PAF B F* A F* B
(apacity
&;/ 44 sec -otal design mm 1010 head wc Fan Speed rpm 1872 Fan @nlet regulation damper type control Fan motor )w :22 rating perating parameters Air Flow &;/ 64905 sec Power )w :02 consumptio n System < 5796 #fficiency %atio of PA 4695 /823
4798 842 1872 Blade pitch control 822 0897 57 6694 8;9; /62K
4798 842 1872 Blade pitch control 822 6792 174 5594
!ser"ation /102&W unit3 Higher PA to SA ratio %esult Adjustment of ratio* power consumption reduced from 02:2 )w to 1562 )w Sa"ing of %s9 ;900 &/A* cosidering 5422 hrs/year and %s9 19;2 per )wh